End protector system for tubular goods

ABSTRACT

An end protector system for tubular goods including, but not necessarily limited to, drilling riser pipe. The end protector system utilizes lightweight substantially rigid, UV-stabilized molded plastic members that can quickly and easily cover box and pin end connections of drilling riser pipe, as well as ancillary conduit holes, bolt holes and/or other openings. The end protector system of the present invention can be used on tubular goods having an end connection flange, as well as those without an end connection flange, to block access to internal surfaces of the drilling riser components. The end protector system of the present invention further includes a retention system to ensure that individual end protectors remain in place during transportation and/or prolonged storage of such tubular goods.

CROSS REFERENCES TO RELATED APPLICATIONS

This application is a continuation of U.S. Non-Provisional patentapplication Ser. No. 12/658,199 filed Feb. 4, 2010, currently pending,which is a continuation of U.S. Non-Provisional patent application Ser.No. 11/639,599 filed Dec. 15, 2006, currently abandoned.

STATEMENTS AS TO RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSOREDRESEARCH AND DEVELOPMENT

None

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention pertains to a system of molded cap devices toprotect the end connections of tubular goods. More particularly, thepresent invention pertains to a system of molded cap devices to protectend connections of drilling riser pipe sections, and to prevent accessto internal portions thereof.

2. Brief Description of the Prior Art

In offshore environments, wells are often drilled from fixed platformsto explore for and develop oil and gas reserves. However, such fixedplatforms may not exist in certain areas where drilling prospects arelocated. As a result, offshore wells are frequently drilled usingmoveable rigs such as drill ships, semi-submersible rigs and jack-uprigs that are not supported by fixed platforms.

Drilling operations conducted from moveable drilling rigs differ fromoperations conducted from platform-supported drilling rigs in manyrespects. Among these differences is the location of the blowoutpreventer assembly and wellhead assembly. Frequently, such equipment isnot located on the rig itself, but rather on the sea floor. In suchcases, specialized equipment known as a drilling riser is used.

Generally, drilling risers consist of several sections of pipe, as wellas special fittings, that are joined together to form a continuouslength of pipe. A riser serves as a conduit to connect a drilling rig(which is located at or near the surface of the water) to a wellheadassembly (which is located at or near the sea floor). When installed, adrilling riser serves as a guide for drilling equipment, as well as aconductor for drilling fluid. In many cases, drilling risers can includespecial devices to compensate for any movement of the drilling rigcaused by waves.

Although the dimensions can vary, individual sections of drilling risercan often be greater than three (3′) feet in diameter and seventy-five(75′) feet in length. Each riser section is typically configured with amale (pin) connection at one end, and a female (box) connection at theopposite end. Although such connections are used to interlock onesection of riser to an adjoining section, flanges are also frequentlyadded at both ends of each riser section; such flanges can be boltedtogether to further secure adjoining sections of riser pipe to eachother.

Wellheads, blow out preventers and other types of subsea equipment aretypically controlled from the surface (i.e., the drilling rig) usingcontrol lines that extend along substantially the entire length of adrilling riser. For this reason, drilling risers frequently includeancillary tubes for housing such control lines; such tubes generallyterminate in openings at both ends of individual riser pipe sections.Further, different wellhead manufacturers utilize drilling risers havingdifferent configurations. As such, the end connections of such drillingriser sections will often vary for different wellhead manufacturers.

After riser pipe is manufactured at a land-based manufacturing facility,the pipe must typically be stored at a pipe yard, loading dock or otherlocation prior to being shipped to a drilling rig or offshore location.Further, such riser pipe must also be stored between drilling projects.During such storage, it is generally beneficial to close the ends ofeach section of riser pipe in order to prevent foreign objects oranimals from entering such pipe. Moreover, it is also beneficial toprotect the end connections and flanges of such riser pipe while suchpipe is being loaded, unloaded and/or transported.

End protectors for threaded tubular goods are known in the art.Similarly, end protectors for sections of riser pipe are also known inthe art. However, such prior art means for protecting riser pipegenerally comprise metal plates that are flat bolted on the flanges ofsuch riser pipe sections, or are curved open-faced sections that arebolted on the flanges to absorb any impact to the main and ancillarypiping. Said metal plates frequently fail to cover all openings on theriser including, but not limited to, ancillary line openings and flangebolt holes. Further, such metal plates are bulky and heavy; such platescan often weigh hundreds of pounds. As such, said plates are frequentlydifficult to handle, install and remove, and can cause injuries topersonnel handling or working with such plates.

Flexible molded polyurethane and rubber covers have also been developedto cover the ends of individual riser pipe sections. Such molded capsare preferable to metal plates, in that said caps can be specificallymolded to fit both male and female configurations. Further, said moldedcaps can be easily customized to fully cover all individual openingsassociated with a particular type of riser pipe, including ancillaryline(s) and flange/bolt holes. However, polyurethane is negativelyaffected by weathering including, without limitation, ultraviolet (“UV”)waves. Thus, such molded polyurethane covers are susceptible to losingtheir shape. When this occurs, such molded covers can fall off the riserpipe sections, thereby leaving such pipe sections exposed.

Thus, there is a need for a versatile end protector system for tubulargoods including, but not necessarily limited to, riser pipe. Such endprotector system must avoid the problems associated with existing metalplates and molded polyurethane caps.

SUMMARY OF THE PRESENT INVENTION

The present invention comprises an end protector system for tubulargoods including, but not necessarily limited to, drilling riser pipe.Such end protector system utilizes substantially rigid, UV-stabilizedmolded plastic members that can cover box and pin end connections ofdrilling riser pipe, as well as ancillary conduit holes, bolt holesand/or other openings. The end protector system of the present inventioncan be used on tubular goods having an end flange, as well as thosewithout an end connection flange. The end protector system of thepresent invention further includes a retention system to ensure thatindividual end protectors remain in place during transportation and/orprolonged storage of such tubular goods.

The end protector system of the present invention protects the endconnections of drilling riser sections, and prevents access to internalsurfaces of the central bore and other ancillary conduit holes of suchdrilling riser pipe. In the preferred embodiment of the presentinvention, said end protector system permits access to lifting eyes onsaid riser pipe; as such, said end cap protector system can remaininstalled on such riser pipe while it is being lifted by a crane orother hoisting device. In an alternative embodiment of the presentinvention, said end protector system has a “unisex” configuration, inthat it can be utilized to fit on both box and pin connections of riserpipe.

The end protector system of the present invention utilizes lightweightend protectors that can be easily handled by personnel. Said endprotectors shield end connections of tubular goods from damage duringtransportation and/or storage of such tubular goods. Further, such endprotectors can remain in the elements, including direct sunlight, forextended periods of time without becoming damaged or destroyed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a side perspective view of an end protector of thepresent invention compatible with a pin end of a section of drillingriser pipe.

FIG. 2 depicts a front perspective view of an end protector of thepresent invention compatible with a box end of a section of drillingriser pipe.

FIG. 2 a depicts a back perspective view of an end protector of thepresent invention compatible with a box end of a section of drillingriser pipe.

FIG. 3 depicts a side sectional view of an end protector of the presentinvention installed on a pin end of a section of drilling riser pipehaving a flange.

FIG. 4 depicts a side sectional view of an end protector of the presentinvention installed on a box end of a section of drilling riser pipehaving a flange.

FIG. 5 depicts a side perspective view of an alternate embodiment of anend protector of the present invention having a cut away section.

FIG. 6 depicts an exploded perspective view of an alternative embodimentof an end protector of the-present invention.

FIG. 7 depicts a side perspective view of a split ring member of analternative embodiment of an end protector of the present invention.

FIG. 8 a depicts a side sectional view of an end protector of thepresent invention installed on a box end of a section of drilling riserpipe without a flange connection.

FIG. 8 b depicts an exploded side sectional view of an end protector ofthe present invention depicted in FIG. 8 a (not including the drillingriser pipe).

FIG. 9 depicts a perspective view of a hole-plug of the presentinvention.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION

Referring to the drawings, FIG. 1 depicts a side perspective view of endprotector 10 of the present invention. End protector 10 depicted in FIG.1 is compatible with a pin end of a section of drilling riser pipehaving a flange. In the preferred embodiment, end protector 10 (as wellas all end protectors depicted in the drawings) is a substantially rigidmolded plastic component. Said plastic includes UV-stabilizationadditives well known to those having skill in the art of plasticmolding.

End protector 10 generally comprises body section 1, tapered surface 2and substantially planar top or end surface 3; body section 1 andtapered surface 2 form interconnected side walls that extend fromtop/end surface 3 and define a recess or cavity. It is to be observedthat the specific dimensions of body section 1, tapered surface 2 andend surface 3 are beneficially designed to fit the appropriatecorresponding dimensions of a tubular good connection (such as, forexample, the pin end connection of a section of drilling riser pipe)upon which said end protector 10 is to be installed. By way ofillustration, but not limitation, body section 1 should have theappropriate diameter to fit around a flange connection of a section ofriser pipe, while tapered surface 2 must extend sufficiently far tocover any pin connection extending from such section of riser pipe.

Still referring to FIG. 1, end protector 10 includes a plurality ofprojections 4. In the preferred embodiment, said projections 4 extendfrom tapered surface 2 of end protector 10 and can cover the ends (andopenings thereof) of control lines or other ancillary lines of a sectionof drilling riser pipe. Further, in the preferred embodiment, aplurality of clip fasteners 5 are disposed along the outer surface ofbody section 1 of end protector 10.

FIG. 2 depicts a front perspective view of an end protector 20 of thepresent invention. End protector 20 is similar to end protector 10,except that end protector 20 is compatible with a box end of a sectionof drilling riser pipe. End protector 20 includes rim section 21,tapered section 22 and end section 23. In the preferred embodiment, thedimensions of tapered section 22 are designed so that end protector 20is held in place by a pre-loaded compression fit of approximately 1/16of an inch. A plurality of apertures 24 are disposed on rim section 21.By way of illustration, but not limitation, UV-protected tie wraps canbe threaded through apertures 24, around ancillary lines of a section ofdrilling riser pipe, and tightened. In this manner, end protector 20 canbe easily, quickly and securely attached to an end of a section ofdrilling riser pipe. FIG. 2 a depicts end protector 20, but from areverse angle relative to the view depicted in FIG. 2.

It is to be observed that the dimensions and basic configurations of endprotectors 10 and 20 can be varied as necessary to meet particularapplications. Thus, the specific dimensions and configurations of saidend protectors can be set during the molding process, and can betailored to fit dimensions and configurations of particular tubulargoods with which said end protectors are to be utilized.

FIG. 3 depicts a side sectional view of end protector 10 of the presentinvention installed on a pin end of a section of drilling riser pipe 100having flange connection 103 near its pin end. Specifically, drillingriser pipe 100 comprises central tubular member 101, as well asancillary tubular control lines 102 and 104. Said tubular membersinclude ends 101 a, 102 a and 104 a; although not visible from thisperspective in FIG. 3, each of said ends 101 a, 102 a and 104 a haveopenings that lead into central longitudinal bores of said tubularmembers.

End protector 10 is installed on drilling riser section 100. As such,the specific dimensions of body section 1, tapered surface 2 and endsurface 3 of end protector 10 are beneficially designed to fit theappropriate corresponding dimensions of drilling riser pipe section 100.Body section 1 has the appropriate diameter to accommodate and fitaround flange connection 103. Similarly, tapered surface 2 must extendsufficiently far to cover end 101 a (pin end connection) of centraltubular member 101, while projections 4 must be spaced and sized tocover ends 102 a and 104 a of ancillary lines 102 and 104.

In this embodiment, clip fasteners 5 are disposed along the outersurface of body section 1 of end protector 10. Such clip fasteners fitaround and behind flange 103 and secure end protector 10 on drillingriser 100. In this configuration, end protector 10 closes off or blocksaccess to internal surfaces of drilling riser 100 accessible throughopenings 101 a, 102 a and 104 a.

FIG. 4 depicts a side sectional view of end protector 20 of the presentinvention installed on a box end of a section of drilling riser pipe 200having a flange 203. Riser pipe 200 includes tubular member 201 defininginternal surface 202. End protector 20 includes rim section 21, taperedsection 22 and end section 23. When installed, end protector 20 closesoff or blocks access to internal surface 202 of drilling riser 200 viathe box end connection of drilling riser 200.

In the preferred embodiment, the dimensions of tapered section 22 aredesigned so that end protector 20 is held in place by a pre-loadedcompression fit of approximately 1/16 of an inch. Although not visiblein FIG. 4, a plurality of apertures 24 are disposed on rim section 21.By way of illustration, but not limitation, UV-protected tie wraps canbe threaded through apertures 24, around ancillary lines of a section ofdrilling riser pipe, and tightened. In this manner, end protector 20 canbe easily, quickly and securely attached to an end of a section ofdrilling riser pipe

FIG. 5 depicts a side perspective view of an alternate embodiment of endprotector 30 of the present invention. Like end protector 10 depicted inFIG. 1, end protector 30 generally comprises a body section 31, taperedsurface 32 and end surface 33. Also, like end protector 10, the specificdimensions of body section 31, tapered surface 32 and end surface 33 arebeneficially designed to fit the appropriate corresponding dimensions ofa tubular good connection (such as, for example, the pin end connectionof a section of drilling riser pipe) upon which said end protector 30 isto be installed. Unlike end protector 10, end protector 30 does notinclude a plurality of projections, such as projections 4 on endprotector 10, thus allowing end protector 10 to be utilized as a“unisex” end protector (that is, a protector that can be used on bothpin or box end connections.)

End protector 30 includes a plurality of eyelets 35 disposed along theouter periphery of body section 31. End protector 30 can be affixed to asection of drilling riser pipe by threading an attachment means throughsaid eyelets and attaching same to said drilling riser pipe. By way ofillustration, but not limitation, UV-protected tie wraps can be threadedthrough eyelets 35, around the ancillary lines of a section of drillingriser pipe, and tightened. In this manner, end cap 30 can be easily,quickly and snuggly attached to an end of a section of drilling riserpipe. An expandable hole plug (not shown) such as, for example, a plugdisclosed in U.S. Pat. No. 6,453,603, can be used as a closure foraperture 37 to complete the encapsulation of end protector 30 and assistin securing end protector 30 to said drilling riser pipe.

End protector 30 also includes at least one cut away section 36 thatextends primarily into tapered surface 32. End protector 30 alsoincludes aperture 37 that is situated within cut away section 36. Saidaperture is beneficially positioned to align with a lifting eye on asection of drilling riser pipe. As such, a shackle or slings attached toa crane or other hoisting mechanism can pass through aperture 37 and beattached to the lifting eye of such section of drilling riser so thatsaid drilling riser can be moved or otherwise manipulated without havingto remove end protector 30 from said drilling riser pipe.

FIG. 6 depicts an exploded perspective view of an alternative embodimentof an end protector 40 of the present invention. End protector 40generally comprises a body section 41, tapered surface 42 and endsurface 43. The specific dimensions of body section 41, tapered surface42 and end surface 43 are beneficially designed to fit the appropriatecorresponding dimensions of a tubular good connection (such as, forexample, the pin end connection of a section of drilling riser pipe)upon which said end protector 40 is to be installed. End protector 40also includes a plurality of eyelets 45 disposed along the outerperiphery of body section 41.

As discussed in detail above, configurations of drilling risers can varydepending upon a number of different factors including, but notnecessarily limited to, the type of drilling rig to be utilized, theconfiguration of subsea wellhead or other equipment to be used, andsurface and subsurface conditions to be encountered. In some cases,adjoining sections of drilling riser pipe are not joined together usingbolted flanges. As such, the end protectors of the present inventioncannot be attached to the ends of said drilling riser sections usingattachment means that are dependent upon the existence of such flanges(such as, for example, clip fasteners 5 of end protector 10 depicted inFIG. 3).

Referring to FIG. 6, split ring 50 can be utilized, particularly inconnection with tubular goods that do not have a flange connection.Split ring 50 generally comprises substantially cylindrical body member52 having rim extension 51. Rim extension 51 is generally sized to beslightly smaller that the opening defined by body section 41 of endprotector 40.

FIG. 7 depicts a side perspective view of a split ring member 50 of thepresent invention, shown from the reverse angle relative to the viewdepicted in FIG. 6. Split ring 50 has substantially cylindrical bodymember 52 having rim extension 51; however, because split ring 50 issplit, cylindrical body member has ends 52 a and 52 b, while rimextension 51 has ends 51 a and 51 b. Mating flange members 53 a and 53 bare disposed at ends 52 a and 52 b, respectively, of cylindrical bodymember 52. Aperture 54 a extends through flange member 53 a, whileaperture 54 b extends through flange 53 b.

When installed around the outer circumference of a section of drillingriser pipe, any gap existing between ends 52 a and 52 b of body member52 closes, and mating flange members 52 a and 52 b are joined together.In this configuration, apertures 54 a and 54 b are aligned with eachother. A fastening means such as, for example, bolt 57 can be threadedthrough said aligned apertures 54 a and 54 b, and easily and quicklysecured in place using wing nut 58. In this manner, split ring 50 can besecured to the body of a section of a drilling riser, including asection of drilling riser lacking a flange connection.

Referring back to FIG. 6, split ring 50 can be installed on a section ofdrilling riser (not depicted in FIG. 6). Thereafter, end protector 40can be installed on split ring 50 and secured in place. Said endprotector 40 can be secured in place by threading an attachment meansthrough eyelets 45 and attaching same to said drilling riser pipe. Byway of illustration, but not limitation, UV-protected tie wraps can bethreaded through eyelets 45, around the ancillary lines of a section ofdrilling riser pipe, and tightened. In this manner, end cap 40 can beeasily, quickly and snuggly attached to an end of a section of drillingriser pipe lacking a flange connection.

FIG. 8 a depicts a side sectional view of end protector 40 of thepresent invention installed on a box end of a section of drilling riserpipe 300. Drilling riser pipe 300 does not include a flange connection.Split ring 50 is installed around the outer circumference of drillingriser pipe section 300, so that mating flange members 52 a and 52 b (notvisible in FIG. 8 a) are joined together. Bolt 57 is threaded throughaligned apertures 54 a and 54 b of flange members 52 a and 52 b, andeasily and quickly secured in place. Once split ring 50 is installed,end protector 40 can be installed on split ring 50 and secured in place.FIG. 8 b depicts an exploded side sectional view of end protector 40 andsplit ring 50 of the present invention depicted in FIG. 8 a (notincluding the drilling riser pipe) to illustrate how end protector 40mates with split ring 50.

FIG. 9 depicts a perspective view of hole-plug 60 of the presentinvention. Hole-plug 60 is similar to end protector 20 depicted in FIGS.2 and 2 a. Hole-plug 60 includes rim section 61, tapered section 62 andend section 63. In the preferred embodiment, the dimensions of taperedsection 62 are designed so that hole-plug 60 is held in place within anopening (such as, for example, a bolt hole of a connection flange of asection of drilling riser pipe) by a pre-loaded compression fit. It isto be observed that hole-plug 60 can be inserted in any openings thatmay be beneficially plugged and further, may be used in addition to anyother end protectors disclosed herein.

The above-described invention has a number of particular features thatshould preferably be employed in combination, although each is usefulseparately without departure from the scope of the invention. While thepreferred embodiment of the present invention is shown and describedherein, it will be understood that the invention may be embodiedotherwise than herein specifically illustrated or described, and thatcertain changes in form and arrangement of parts and the specific mannerof practicing the invention may be made within the underlying idea orprinciples of the invention.

1. An apparatus, for covering a drilling riser end connection flange having a diameter, comprising: a. a cap comprising a substantially planar end and interconnecting side walls extending from said end, said end and walls defining a cavity, wherein said cap has a diameter larger than the diameter of said flange; and b. a plurality of clip members attached to said sidewalls, said clip members adapted to be partially received on said end connection flange and fasten said cap to said flange.
 2. The apparatus of claim 1, wherein said cap comprises ultra violet stabilized molded plastic.
 3. The apparatus of claim 1, said cap further comprising at least one projection for receiving an ancillary tube attached to said drilling riser. 